Gas Cap woes

So I picked up a 82 Seca 550 for parts with no key, but was able to get a key made for $28 from the code on the ignition. While it fits the ignition, helmet lock and gas cap, the key does not turn very far in the gas cap and the locksmith claims its not the key but its the locking mechanism that is seized from rust and age. The locksmith used a pick to determine that all sliders moved, but I'm not so sure that the ignition key code and tank key code are a necessarily a match, regardless of the fact that the key does turn a little.

Regardless, I still can't get the gas cap off to clean and render the tank salvageable, which is the real goal but another was to reuse the helmet lock, ignition, and gas cap tumbler mechanisms on my running bike which currently has issues with all 3 of those parts. So, I don't want to destroy the mechanism. The master key is different between the 2 bikes (x117-YH48 vs. X119-YH47, for those who know what that means) so I need to swap all 3 locks, not just replace or reposition sliders

Any ideas on how to free it up or open it up without destroying the lock mechanism or damaging the tank? I don't care about the actual chrome cap so much because it is shot, but I need to have 3 matching locking mechanisms to reuse and a way to get this cap off.

 

spray some kroil into the key slot and try it again the next day

 

Also try to turn the key as you push down on the cap.

 

Erf. I don't know about getting the existing tank lock open, but in the event you do, here's a couple of files that may come in handy.

How to clean and lube your ignition switch

Read through that, and you'll find out how to pull the lock plug out of the switch. Knowing that will come in handy for this:

Your Gas Cap and You

 

Finally got it open - the key works; its the correct cut, it was the lock mechanism that was stuck and would not open. Finally got it to pop with enough rubber mallet pounding

 

That's good to hear. It seems the locksmith's initial assessment was in fact correct.

Now to deal with the lock plug so this doesn't happen again any time soon.

 

Yep - now the ignition switch and gas cap are all rebuilt thanks to your writeups - even ate some pizza afterward!

 

As long as you've got your priorities straight.

 

If there is rust I'd suggest removing the gas cap and give it at least an overnight soak in evapo-rust,making sure to let it a few time while in the solution.... After rinse with carb cleaner and let dry, lube with either kroil, graphite, or electrical grease...My gas cap lock was stuck from rust when I first got my bike this is just how I solved and prevented future problems with this issue